GEM 1205 User manual

GEMÜ 1205
Electrical position indicator ATEX
Operating instructions
EN
further information
webcode: GW-1205

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
16.03.2023
www.gemu-group.com2 / 20GEMÜ 1205

Contents
1 General information ............................................. 4
1.1 Information .................................................... 4
1.2 Symbols used ................................................ 4
1.3 Warning notes ............................................... 4
2 Safety information ............................................... 4
3 Product description ............................................. 5
3.1 Construction .................................................. 5
3.2 Description ..................................................... 5
3.3 Function ......................................................... 5
3.4 Product label ................................................. 5
4 Correct use .......................................................... 6
5 Order data ........................................................... 7
6 Technical data ..................................................... 8
7 Dimensions .......................................................... 9
8 Manufacturer's information .................................. 10
8.1 Delivery .......................................................... 10
8.2 Packaging ...................................................... 10
8.3 Transport ....................................................... 10
8.4 Storage ........................................................... 10
9 Assembly and installation .................................... 10
9.2 Information on use in damp conditions ....... 11
9.3 Assembly of mounting kit with thread ......... 11
9.3.1 Assembly of mounting kit without
stroke limiter .................................... 11
9.3.2 Assembly of mounting kit with
stroke limiter .................................... 11
9.4 Assembly of mounting kit without thread ... 11
9.5 Assembly and installation of the electrical
position indicator .......................................... 12
10 Electrical connection ........................................... 14
10.1 Terminals, microswitch (code 104) ............. 14
11 Troubleshooting .................................................. 15
12 Inspection and maintenance ................................ 15
12.1 Spare parts .................................................... 15
12.2 Setting the limit switches ............................. 15
12.3 Cleaning the product ..................................... 15
13 Disassembly ........................................................ 15
14 Disposal .............................................................. 15
15 Returns ................................................................ 15
16 EU Declaration of Conformity in accordance with
2014/34/EU (ATEX) ............................................. 17
17 EU type examination certificate ............................ 18
GEMÜ 1205www.gemu-group.com 3 / 20

www.gemu-group.com4 / 20GEMÜ 1205
1 General information
1 General information
1.1 Information
- The descriptions and instructions apply to the standard ver-
sions. For special versions not described in this document
the basic information contained herein applies in combina-
tion with any additional special documentation.
- Correct installation, operation, maintenance and repair work
ensure faultless operation of the product.
- Should there be any doubts or misunderstandings, the Ger-
man version is the authoritative document.
- Contact us at the address on the last page for staff training
information.
1.2 Symbols used
The following symbols are used in this document:
Symbol Meaning
Tasks to be performed
Response(s) to tasks
– Lists
1.3 Warning notes
Wherever possible, warning notes are organised according to
the following scheme:
SIGNAL WORD
Type and source of the danger
Possible
symbol for the
specific
danger
Possible consequences of non-observance.
Measures for avoiding danger.
Warning notes are always marked with a signal word and
sometimes also with a symbol for the specific danger.
The following signal words and danger levels are used:
DANGER
Imminent danger!
▶Non-observance can cause death or
severe injury.
WARNING
Potentially dangerous situation!
▶Non-observance can cause death or
severe injury.
CAUTION
Potentially dangerous situation!
▶Non-observance can cause moderate
to light injury.
NOTICE
Potentially dangerous situation!
▶Non-observance can cause damage to
property.
The following symbols for the specific dangers can be used
within a warning note:
Symbol Meaning
Danger – high voltage
2 Safety information
The safety information in this document refers only to an indi-
vidual product. Potentially dangerous conditions can arise in
combination with other plant components, which need to be
considered on the basis of a risk analysis. The operator is re-
sponsible for the production of the risk analysis and for com-
pliance with the resulting precautionary measures and re-
gional safety regulations.
The document contains fundamental safety information that
must be observed during commissioning, operation and main-
tenance. Non-compliance with these instructions may cause:
- Personal hazard due to electrical, mechanical and chemical
effects.
- Hazard to nearby equipment.
- Failure of important functions.
- Hazard to the environment due to the leakage of dangerous
substances.
The safety information does not take into account:
- Unexpected incidents and events, which may occur during
installation, operation and maintenance.
- Local safety regulations which must be adhered to by the
operator and by any additional installation personnel.
Prior to commissioning:
1. Transport and store the product correctly.
2. Do not paint the screws and plastic parts of the product.
3. Carry out installation and commissioning using trained
personnel.
4. Provide adequate training for installation and operating
personnel.
5. Ensure that the contents of the document have been fully
understood by the responsible personnel.
6. Define the areas of responsibility.
7. Observe the safety data sheets.
8. Observe the safety regulations for the media used.

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During operation:
9. Keep this document available at the place of use.
10. Observe the safety information.
11. Operate the product in accordance with this document.
12. Operate the product in accordance with the specifications.
13. Maintain the product correctly.
14. Do not carry out any maintenance work and repairs not de-
scribed in this document without consulting the manufac-
turer first.
In cases of uncertainty:
15. Consult the nearest GEMÜ sales office.
3 Product description
3.1 Construction
1
2
3
4
Item Name Materials
1 Cover Aluminium diecast-
ing
2 Base Aluminium diecast-
ing
3 Operating bush 1.4104
4 Guide piece 1.4305
3.2 Description
The GEMÜ 1205 electrical position indicator has electro-
mechanical microswitches in a flameproof enclosure. Two
valve positions, open and/or closed can be remotely indic-
ated.
3.3 Function
The GEMÜ 1205 electrical position indicator is used to feed
back and verify the position of valves operated with pneu-
matic linear actuators. The spindle of the electrical position
indicator is positively connected to the spindle of the linear
actuator and is moved with the linear movement of the actu-
ator. The cam attached to the spindle then actuates the built-
in microswitches, which are used for electronic signal trans-
mission.
Depending on the version, the electrical position indicator is
equipped with 1 to 2 microswitches.
3.4 Product label
Device version Design in accordance with order
data
Item number Traceability number Serial number
Device-specific data
Year of manufacture
The month of manufacture is encoded in the traceability num-
ber and can be obtained from GEMÜ. The product was manu-
factured in Germany.
3 Product description

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4 Correct use
4 Correct use
DANGER
Danger of explosion
▶Risk of death or severe injury.
●Do not use the product as a step or
foothold.
●Prior to commissioning, ensure that
the cover is fully closed and that the
housing and the O-ring are not dam-
aged.
WARNING
Improper use of the product!
▶Risk of severe injury or death
▶Manufacturer liability and guarantee will be void
●Only use the product in accordance with the operating
conditions specified in the contract documentation and in
this document.
The GEMÜ 1205 electrical position indicator is designed for
use in potentially explosive atmospheres of zones 1 and 2
with gases, mists or vapours and zones 21 and 22 with flam-
mable dusts.
The product has the following explosion protection marking:
Gas: II 2G Ex db eb IIC T6 Gb
Dust: II 2D Ex tb IIIC T80°C Db
EC type examination certific-
ate
IBExU18ATEX1008
For special conditions and operation limits see EC type exam-
ination certificate.
Use of the product is permissible in the following ambient
temperature ranges: T6/T80 °C: -20°C to +60°C
●Use the product in accordance with the technical data.
4.1 Use in potentially explosive environments
The product is certified in accordance with ATEX and has an
explosion protection approval according to 2014/34/EU (see
"Technical data").
The energy supply must be equipped with a switch or an over-
current protective device in the system.
The product user is responsible for providing connections that
comply with standards as well as cable compatibility and
warning signs. Only Ex t or Ex e cable glands with properties
corresponding to at least those of the housing must be used
(IP protection, ambient temperature, explosion protection
class, thread type and size). The materials of the cable glands
must be compatible with the housing materials. The cable
glands must comply with at least IP65. The connection is de-
signed as M20. Installation, operation and maintenance must
only be carried out by qualified trained personnel with a
strong knowledge of the type of ignition protection
"Flameproof enclosure" db, eb and tb. Do not repair the device
yourself if it is faulty. Instead, replace it with an equivalent
new device. Repairs must only be carried out by the manufac-
turer! The device must only be used if its materials are resist-
ant against mechanical and/or chemical influences or corro-
sion under the respective operating conditions to such a suffi-
cient degree that the explosion protection is not impaired or
nullified.

5 Order data
The order data provide an overview of standard configurations.
Please check the availability before ordering. Other configurations available on request.
Note: Mounting kit 1205 S01 Z...AT dependent on valve type. Please order separately specifying valve type, DN, control function
and actuator size.
Order codes
1 Type Code
Electrical position indicator ATEX
for linear actuators
1205
2 Fieldbus Code
Without 000
3 Accessory Code
Accessory Z
4 Housing material Code
Aluminium diecasting AL
5 Function Code
Open / Closed A00
Open A01
5 Function Code
Closed A02
6 Electrical connection Code
M20 cable gland 03
7 Options Code
Without 00
8 Switch Code
Change-over contact, microswitch M2
9 Connection diagram Code
Microswitch PNP M2
10 Special version Code
ATEX 2014/34/EU X
Order example
Ordering option Code Description
1 Type 1205 Electrical position indicator ATEX
for linear actuators
2 Fieldbus 000 Without
3 Accessory Z Accessory
4 Housing material AL Aluminium diecasting
5 Function A00 Open / Closed
6 Electrical connection 03 M20 cable gland
7 Options 00 Without
8 Switch M2 Change-over contact, microswitch
9 Connection diagram M2 Microswitch PNP
10 Special version X ATEX 2014/34/EU
5 Order data
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6 Technical data
6.1 Temperature
Ambient temperature: -20 to 60 °C
Storage temperature: 0 — 40 °C
6.2 Product compliance
Explosion protection: Special version X order code
ATEX marking: Gas: II 2G Ex db eb IIC T6 Gb
Dust: II 2D Ex tb IIIC T80°C Db
Type examination
certificate:
IBExU18ATEX1008
6.3 Mechanical data
Weight: 1146.5 g
Protection class: IP 65 acc. to EN 60529
Range of limit switch: 2 to 70 mm continuous
Mechanical stability: 7 Nm, impact energy acc. to EN 60079-0
Max. switching fre-
quency:
≤ 1000 switching cycles/h
6.4 Electrical data
Switch type: Microswitch
Switch rating: Switch rating AC
Voltage Ohmic load Inductive load (cosϕ = 0.6)
250 V
30 V
5 A
7 A
3 A
5 A
Switch rating DC
Voltage Ohmic load Inductive load (cosϕ = 0.6)
250 V
30 V
0.4 A
7 A
0.03 A
5 A
Information applies to 40 °C ambient temperature
Thermal rated current: 6 A
Electrical connection
type:
M20 cable gland 1 x available (Type Bartec 03-6020-0016)
1 x prepared (blanking cover)
Cable diameter: 7 to 13 mm
Terminal diameter: 2.5 mm²
Earth terminal: 4.0 mm²
Potential equalisation: Stranded wire, yellow/green, H 07 V-K 4.0
Tightening torque 10 Nm
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6 Technical data

7 Dimensions
M4 x 6
Ø100,0
20,0
20,0
55,0
14,0
119,0
125,0
Dimensions in mm
GEMÜ 1205www.gemu-group.com 9 / 20
7 Dimensions

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8 Manufacturer's information
8 Manufacturer's information
8.1 Delivery
●Check that all parts are present and check for any damage
immediately upon receipt.
The product's performance is tested at the factory. The scope
of delivery is apparent from the dispatch documents and the
design from the order number.
8.2 Packaging
The product is packaged in a cardboard box which can be re-
cycled as paper.
8.3 Transport
1. Only transport the product by suitable means. Do not drop.
Handle carefully.
2. After the installation dispose of transport packaging ma-
terial according to relevant local or national disposal regu-
lations / environmental protection laws.
8.4 Storage
1. Store the product free from dust and moisture in its ori-
ginal packaging.
2. Avoid UV rays and direct sunlight.
3. Do not exceed the maximum storage temperature (see
chapter "Technical data").
4. Do not store solvents, chemicals, acids, fuels or similar
fluids in the same room as GEMÜ products and their spare
parts.
9 Assembly and installation
DANGER
Risk of electric shock
▶Risk of injury or death (if operating
voltage is higher than safe extra low
voltage).
▶Electric shock can cause severe burns
and fatal injury.
●Work on electrical connections only by
qualified trained personnel.
●Disconnect the cable from the power
supply before making the electrical
connection.
●Connect the protective earth con-
ductor.
CAUTION
Danger - high voltage!
▶Electric shock.
●Before performing any work on the
GEMÜ product switch off power and
protect circuit from being switched on
again.
CAUTION
Fitted electrical position indicator
▶Destruction of the electrical position indicator when dis-
assembling the valve body
●Disassemble the electrical position indicator before dis-
assembling the valve body
NOTICE
●Pay attention to the information on product labels, in
product documentation and EC type examination certific-
ate.
●Connect cable carefully, do not damage individual wires.
●When connecting multiwire or finewire cables, prepare
the wire ends.
●Always use suitable pinch tools for pinching wire end fer-
rules in order to achieve consistent quality.
●Tighten all clamping points, even the ones not being
used.
9.1 Preparations for mounting to the valve
1. Move the actuator A into zero position (actuator vented).
2. Remove optical position indicator 2 and / or protective cap
1 from the actuator top.

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A
12
9.2 Information on use in damp conditions
The following information is intended to help when installing
and operating the product in damp conditions.
1. Lay cables and pipework so that no condensate or rain
water that remains on the pipework / cables can enter the
cable glands or plugs of the product.
2. Check that all cable glands or plugs are positioned cor-
rectly
3. Check the sealing ring 1 for any damage and correct posi-
tioning before tightening the cover.
1
9.3 Assembly of mounting kit with thread
1. Before beginning assembly, check the type of mounting
kit.
9.3.1 Assembly of mounting kit without stroke limiter
1
2
3
1. Screw in adapter 2 using wrench surface 1.
2. Screw in guide piece 3 using the wrench surface.
9.3.2 Assembly of mounting kit with stroke limiter
2
1
4
56
1. Screw in adapter 2 using wrench surface 1.
2. Set stroke limiter to the desired height using wrench sur-
face4.
3. Secure nut 5 against the actuator top.
4. Only use thread sealing ring 6 for installation of stroke lim-
iters in case of control functions 2 and3
9.4 Assembly of mounting kit without thread
1
1
2
1. Insert spindle of mounting kit 1 into actuator.
2. Carefully knock down the spindle of mounting kit 1 with an
appropriate tool 2 until it stops.
3
4
3. Screw in guide piece 3 using the wrench surface.
4. Mounting kit 1 is correctly assembled.
9 Assembly and installation

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9 Assembly and installation
9.5 Assembly and installation of the electrical position
indicator
DANGER
Danger of explosion
▶Risk of death or severe injury.
●Do not use the product as a step or
foothold.
●Prior to commissioning, ensure that
the cover is fully closed and that the
housing and the O-ring are not dam-
aged.
DANGER
Risk of electric shock
▶Risk of injury or death (if operating
voltage is higher than safe extra low
voltage).
▶Electric shock can cause severe burns
and fatal injury.
●Work on electrical connections only by
qualified trained personnel.
●Disconnect the cable from the power
supply before making the electrical
connection.
●Connect the protective earth con-
ductor.
1
2
1
2
1. Disconnect the power sup-
ply and secure against re-
commissioning.
2. Undo nuts 1 and leave
them in cover 2.
3. Remove cover 2.
4. Undo grub screw 1 (do not
unscrew completely).
5. Put the base of the elec-
trical position indicator
onto guide piece 2 (taking
care that the trip cams do
not damage the switches!
6. Turn the electrical position
indicator into the desired
connection direction and
fix the position with grub
screw 1.
Setting the upper switching
position:
Setting the lower switching
position:
1
2
3
4
6
5
1
2
3
4
6
5
7. Move the valve to the
OPEN position.
8. Undo screws 1.
9. Use the left screw 2 to
move switch 3 to the de-
sired position.
10. Tighten screws 1.
ðThe upper switching po-
sition is set.
11. Move the valve to the
CLOSED position.
12. Undo screws 4.
13. Use the right screw 5 to
move switch 6 to the de-
sired position.
14. Tighten screws 4.
ðThe lower switching po-
sition is set.
PLEASE NOTE: For reasons of electrical safety, it is mandat-
ory to connect a protective earth conductor to the terminal
point in the housing marked with the protective earth sym-
bol!
15. Insert the connection cable through the cable gland.
16. Only strip the connection cable directly before the switch
mounting plate.
17. Guide the individual wires to the terminals.
18. Cut the individual wires to the appropriate length in order
to avoid having unnecessarily long cable loops.
19. Compress the individual wires with wire end ferrules.
20. Connect the individual wires to the terminals in accord-
ance with the connection diagram.
6
5
4
3
2
1
x1
4
2
1S2
S1
4
2
1
On-site
wiring
On-site
wiring
Limit switch OPEN Limit switch CLOSED

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3
2
1
21. After completing the electrical connection, carefully pull
the connection cable taut.
ðAvoid pulling too hard!
22. Make sure that the O-ring is properly mounted and not
damaged.
23. Attach the cover 2 with the nuts 3.
24. Screw in and tighten nuts 3.
ðEnsure all seals and threaded connections are cor-
rectly installed.
25. Supply power to the electrical position indicator.
26. For function control, open and close the valve and pay at-
tention to signalling.
27. If the settings need to be readjusted, disconnect the elec-
trical position indicator from the power supply and repeat
step 7 to step 26.
M4x6
28. Use a screw M4x6 to attach the potential equalization
device to the electrical position indicator.
ðPotential equalization for metal housings in potentially
explosive areas: Minimum 4 mm².
29. Secure the connection against working itself loose.
9 Assembly and installation

10 Electrical connection
10.1 Terminals, microswitch (code 104)
6
5
4
3
2
1
x1
4
2
1S2
S1
4
2
1
On-site
wiring
On-site
wiring
Limit switch OPEN Limit switch CLOSED
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10 Electrical connection

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11 Troubleshooting
Error Error cause Error clearance
No stroke No mounting kit
available
Check mounting kit
Process valve
faulty
Replace process
valve
Wrong mounting kit
installed
Replace mounting
kit
No feedback Incorrect assembly Check assembly,
wiring and connec-
tion
Switch not set Set switch
Wrong mounting kit
installed
Replace mounting
kit
Voltage is not con-
nected
Connect voltage
Cover cannot be at-
tached
Sealing ring inser-
ted incorrectly
Insert sealing ring
correctly
Sealing ring dam-
aged
Replace sealing
ring
Cables protruding
over the edge of the
base
Check the cable
routing and shorten
the cables if neces-
sary
Grub screw not
working
Grub screw un-
screwed too far, nut
fell out
Reinsert the nut,
screw in the grub
screw (during as-
sembly, only undo
the grub screw, do
not unscrew it com-
pletely)
12 Inspection and maintenance
CAUTION
Use of incorrect spare parts!
▶Damage to the GEMÜ product
▶Manufacturer liability and guarantee will be void
●Use only genuine parts from GEMÜ.
NOTICE
Exceptional maintenance work!
▶Damage to the GEMÜ product
●Any maintenance work and repairs not described in these
operating instructions must not be performed without
consulting the manufacturer first.
The operator must carry out regular visual examination of the
products dependent on the operating conditions and the po-
tential danger in order to prevent leakage and damage.
1. Have servicing and maintenance work performed by
trained personnel.
2. Wear appropriate protective gear as specified in plant op-
erator's guidelines.
3. Shut off plant or plant component.
4. Secure the plant or plant component against recommis-
sioning.
5. Depressurize the plant or plant component.
6. Actuate products which are always in the same position
four times a year.
12.1 Spare parts
No spare parts are available for this product. If it is faulty,
please return it to GEMÜ for repair.
12.2 Setting the limit switches
For limit switch setting see chapter "Assembly and installation
of the electrical position indicator" steps 1 to 14.
12.3 Cleaning the product
- Do not clean the product with a high pressure cleaning
device.
13 Disassembly
1. Switch off power to the product.
2. Remove the potential equalisation device.
3. Remove the cover 2.
4. Remove the individual wires from the terminal strip.
5. Remove the connection cable.
6. Dismantle the mounting kit/product in the opposite order
to that described in the Assembly (see “Assembly and in-
stallation“, page10) chapter.
14 Disposal
1. Pay attention to adhered residual material and gas diffu-
sion from penetrated media.
2. Dispose of all parts in accordance with the disposal regu-
lations/environmental protection laws.
3. Dispose of electronic components separately.
15 Returns
Legal regulations for the protection of the environment and
personnel require that the completed and signed return deliv-
ery note is included with the dispatch documents. Returned
goods can be processed only when this note is completed. If
15 Returns

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15 Returns
no return delivery note is included with the product, GEMÜ
cannot process credits or repair work but will dispose of the
goods at the operator's expense.
1. Clean the product.
2. Request a return delivery note from GEMÜ.
3. Complete the return delivery note.
4. Send the product with a completed return delivery note to
GEMÜ.

16 EU Declaration of Conformity in accordance with 2014/34/EU (ATEX)
EU Declaration of Conformity
in accordance with 2014/34/EU (ATEX)
We, the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Strasse 6–8
74653 Ingelfingen-Criesbach, Germany
declare that the product listed below complies with the requirements of directive 2014/34/EU for intended use in potentially ex-
plosive areas.
Description of the product: Electrical position indicator GEMÜ 1205
Marking - 1205 000 Z AL A00 03 00 M2 M2 X
- 1205 000 Z AL A01 03 00 M2 M2 X
- 1205 000 Z AL A02 03 00 M2 M2 X
EC type examination certificate IBExU18ATEX1008.
The notified body IBExU, No. 0637 has certified the above mentioned product and issued the following certificate:
IBExU18ATEX1008.
The Essential Safety and Health Requirements are met by compliance with the standards listed below that are applicable for the
above mentioned product:
- EN 60079-0:2012+A11:2013
- EN 60079-1:2014
- EN 60079-7:2015
- EN 60079-31:2014
2023-03-10
Joachim Brien
Head of Technical Department
GEMÜ 1205www.gemu-group.com 17 / 20
16 EU Declaration of Conformity in accordance with 2014/34/EU (ATEX)

www.gemu-group.com18 / 20GEMÜ 1205
17 EU type examination certificate
17 EU type examination certificate

www.gemu-group.com 19 / 20 GEMÜ 1205
17 EU type examination certificate

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach, Germany
Phone [phone] · [email protected]
www.gemu-group.com
Subject to alteration
03.2023 | 88593512